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Troubleshooting

Solutions for common issues and problems with the RTMC130 Motion Control System.

Documentation

Troubleshooting Guide

This guide helps you diagnose and resolve common issues with the RTMC130 Motion Control System. Follow the step-by-step solutions to get your system back up and running quickly.

Note: Before attempting any troubleshooting, ensure the system is in a safe state. Consider disabling motor power if troubleshooting movement issues to prevent unexpected motion.

System Startup Issues

Problems that prevent the RTMC130 software from launching or initializing properly.

Problem: Software Fails to Launch

Symptoms: When typing rtmc130 at the DOS prompt, the software doesn't start or returns to DOS prompt immediately.

Possible Causes & Solutions:

Cause Solution
Incorrect directory
  • Ensure you're in the \rtmc48 directory
  • Type cd \rtmc48 to navigate to the correct location
Insufficient memory
  • Exit any other programs running in DOS
  • Modify CONFIG.SYS to optimize memory (consult DOS manual)
  • Boot with a clean boot disk
Missing files
  • Verify that RTMC130.EXE and supporting files exist in the directory
  • Check for RTMC130.LIB, SOFTWARE.CFG, and other critical files
  • Reinstall from original media if necessary

Problem: "Improper DOS Version" Error

Symptoms: Software displays "Improper DOS Version" or similar error message.

Possible Causes & Solutions:

  • Running from Windows: RTMC130 requires pure DOS mode.
    • Exit Windows and boot to pure DOS mode
    • Create a DOS boot disk and boot from it
  • Incompatible DOS version: RTMC130 works best with MS-DOS 6.22.
    • Verify your DOS version by typing ver at the DOS prompt
    • Consider installing MS-DOS 6.22 or a compatible version

Problem: No Control Panel After Startup

Symptoms: The software appears to start (disk activity, etc.) but no Control Panel interface appears.

Possible Causes & Solutions:

  • Missing mouse driver: The interface requires a mouse.
    • Ensure a DOS mouse driver is loaded (typically MOUSE.COM)
    • If necessary, type mouse at the DOS prompt before launching
  • Hardware conflict: The RTMC card may have an IRQ conflict.
    • Check for conflicts with sound cards or other devices on IRQ5
    • Adjust jumper settings on the RTMC card (see Hardware Setup)
  • Display issue: Graphics mode may not be compatible.
    • Boot with a standard VGA driver
    • Remove any high-resolution drivers from CONFIG.SYS/AUTOEXEC.BAT

Hardware Connection Problems

Issues related to physical connections, jogbox, and motor control hardware.

Problem: Jogbox Doesn't Respond

Symptoms: Pressing buttons on the jogbox produces no response, or the LCD display remains blank.

Possible Causes & Solutions:

  • Incorrect connection: The jogbox may be connected to the wrong port.
    • Ensure jogbox is connected to the DB25 connector on the RTMC card, not to a printer port
    • Check that the jogbox cable is securely connected
  • Damaged cable: The cable may have internal breaks.
    • Inspect the cable for visible damage
    • Test with a known working jogbox cable if available
  • Power issue: The jogbox may not be receiving power.
    • The jogbox is powered through the cable from the RTMC card
    • Verify the RTMC card is properly installed and powered
Jogbox Connection

Problem: Motors Don't Move

Symptoms: One or more motors don't respond to jog commands or during playback.

Possible Causes & Solutions:

Cause Solution
Axis in OFF mode
  • Check the mode column in the Control Panel
  • Change the axis to REC or NEUT mode
  • Press AXIS ON + axis number on the jogbox
Motor drivers powered off
  • Verify power to the motor driver units
  • Check any emergency stop buttons or power switches
  • Ensure all motor power supplies are on
Incorrect motor patching
  • Check motor patching settings (see Motor Patching)
  • Verify the axis is patched to the correct physical motor
  • Try setting the axis to a different motor number as a test
Cable connection issue
  • Check DB37 cable connections to the RTMC card
  • Verify connections to motor drivers
  • Look for damaged pins or loose connections

Testing Tip: To isolate motor issues, try a simple test by patching different axes to the same physical motor. If one axis can move it but another can't, the issue is software-related rather than physical.

Problem: Motor Moves in Wrong Direction

Symptoms: The motor moves opposite to the expected direction when jogged or during playback.

Solutions:

  1. Adjust in software:
    • Go to AxisSetup
    • Select the problematic axis
    • Find the "Joystick Gain" or "Direction" parameter
    • Change it from positive to negative (or vice versa)
  2. Hardware adjustment: If software change isn't possible:
    • Power down the system completely
    • Swap the step/direction wires at the motor driver
    • Restart the system and test

Movement and Playback Problems

Issues that affect the quality or behavior of movement playback.

Problem: Jerky Motion During Playback

Symptoms: Movement is not smooth, appears to stutter or jerk during playback.

Possible Causes & Solutions:

  • Too few keyframes or poor interpolation:
    • Add more keyframes to better define the path
    • Use Spline curve type instead of Linear
    • Apply the sm (Smooth Move) command to the affected axes
  • Improper acceleration/deceleration settings:
    • In AxisSetup, adjust the Acceleration and Deceleration values
    • Higher values (slower acceleration) often produce smoother motion
  • System performance issues:
    • Reduce the number of axes being controlled simultaneously
    • Check for IRQ conflicts or high CPU usage
    • Ensure no other programs are running in background

Smoothing Tip: The ps (Pull Set) command followed by sm (Smooth Move) can dramatically improve jerky motion in recorded moves.

Problem: Position Drift Over Time

Symptoms: After multiple runs, the axes gradually drift from their expected positions.

Possible Causes & Solutions:

  • Stepper motor missed steps:
    • Reduce the speed and acceleration settings
    • Check that motor power supplies are providing sufficient voltage
    • Ensure the mechanical system isn't binding or overloaded
  • Encoder issues (if using encoders):
    • Verify encoder connections and wiring
    • Clean any optical encoders that may have accumulated dust
    • Check encoder resolution settings in the software
  • Calibration drift:

Problem: Unexpected Movement During Recording

Symptoms: Axes move unexpectedly or record movement you didn't intend during joystick recording.

Solutions:

  • Check REC/NEUT mode settings:
    • Ensure only the axes you want to record are in REC mode
    • Set all other axes to NEUT or OFF
  • Joystick/encoder issues:
    • Check that the joystick or encoder is centered properly
    • Verify the joystick is assigned to the correct axis
    • Adjust or calibrate any joysticks that are drifting
  • Position/Velocity mode confusion:
    • Verify that you're in the expected mode (Position vs. Velocity)
    • Press POSN/VELO to toggle if needed

Important: Always verify which axes are in REC mode before starting a recording session. Accidental recording on the wrong axis can overwrite carefully created movements.

Software and File Problems

Issues related to software operation, file handling, and system crashes.

Problem: System Freezes or Crashes

Symptoms: Software becomes unresponsive, screen freezes, or system returns to DOS unexpectedly.

Possible Causes & Solutions:

Cause Solution
Memory conflicts
  • Remove memory managers like EMM386 or QEMM from CONFIG.SYS
  • Boot with minimal configuration
  • Create a dedicated boot disk with optimized memory settings
Hardware conflicts
  • Check for conflicts on IRQ5 (default for RTMC card)
  • Verify no other devices are using the same memory address
  • Adjust jumper settings if necessary
Software bugs or buffer overflows
  • Avoid extremely complex moves or too many axes at once
  • Save work frequently as insurance against crashes
  • Update to the latest version of RTMC130 if available

Recovery Tip: After a crash, when restarting RTMC130, immediately type rq (Reload Quit) at the main prompt. This can sometimes recover your unsaved work from the previous session.

Problem: Cannot Save or Load Files

Symptoms: Error messages when attempting to save or load moves or setup files.

Solutions:

  • Disk space issues:
    • Check available disk space with dir command in DOS
    • Delete unnecessary files to free up space
  • File permission problems:
    • Ensure the drive isn't write-protected
    • Check for read-only attributes on files
  • Filename issues:
    • Remember DOS 8.3 filename limitations
    • Avoid special characters in filenames
    • Don't include the extension (the system adds it automatically)

Problem: Move Data Corruption

Symptoms: Loaded moves play back incorrectly or contain unexpected data.

Solutions:

  1. Try a backup:
    • Load a previously saved version of the move
    • Check for auto-saved temporary files
  2. File repair:
    • Try the dr (Diagnostic Report) command
    • Look for any error messages or inconsistencies
  3. Last resort:
    • Use the fi (Fix Move) command, which attempts to repair corrupted moves
    • Note that this may result in some data loss

Prevention: Always save important moves with multiple filenames (versioning) and make regular backups to external media. Corruption is much easier to prevent than to fix.

Using Diagnostic Tools

The RTMC130 system includes several built-in diagnostic tools that can help identify and resolve issues.

Available Diagnostic Commands

Command Purpose Usage
rq Reload Quit Attempt to recover data after a crash
dr Diagnostic Report Generate a system status report
ip Inspect Ports Show raw hardware port status
sc System Check Check system configuration and hardware
tm Test Motors Run a diagnostic test on motor outputs
fi Fix Attempt to repair corrupted move data

Using the Diagnostic Report

The Diagnostic Report (dr) is one of the most useful troubleshooting tools:

  1. Type dr at the main Control Panel prompt and press Enter
  2. The system will generate a comprehensive report that includes:
    • Software version and memory usage
    • Hardware configuration and detected devices
    • Motor/axis settings and assignments
    • System error flags and warnings
  3. Review the report for any error messages or unusual settings
  4. Press Esc to exit the report

Testing Motors

The Test Motors command (tm) allows you to verify hardware connections:

  1. Type tm at the main Control Panel prompt
  2. Select which motor to test (or all motors)
  3. The system will send pulses to each motor in sequence
  4. Observe if the motors respond correctly
  5. This bypasses normal motor patching, testing the raw hardware outputs

Caution: Before running the Test Motors command, ensure there is adequate clearance for all motors to move. The test may move motors regardless of software limits.

When to Contact Support

If you've worked through the troubleshooting steps and still experience issues:

  1. Document your problem:
    • Write down all error messages exactly as they appear
    • Note the exact sequence of events that triggers the issue
    • Run dr and save the diagnostic report if possible
  2. Backup your work:
    • Save all important moves and setups
    • Consider creating a separate backup on external media
  3. Contact technical support:
    • Provide your system details (DOS version, hardware configuration)
    • Explain all steps you've already tried
    • Be prepared to try recommended solutions
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